Thermal regulating three-dimensional insulative structures and articles comprising the same

ABSTRACT

Insulation and filling material that includes a plurality of assemblages of a blend of a plurality of fiber are disclosed. The blend of fibers includes 20 to 80 wt % cellulosic fibers including a phase change material having a fiber size less than 6 denier and a specific latent heat of greater than 20 J/g in a temperature range from 15 to 45 degrees Celsius, and 20 to 80 wt % synthetic polymeric fibers having a fiber size less than 6 denier. The assemblages form three-dimensional structures with internal air spaces. The assemblages may be fiberballs or discrete longitudinally elongated floccules with a relatively open enlarged medial portion and relatively condensed twisted tail portions extending from opposing ends of the medial portion. The insulation or filling material has at least 0.8 clo/oz/sqyd.

CROSS-REFERENCE TO RELATED APPLICATION

The present application perfects and claims priority benefit of U.S. Provisional Patent Application No. 62/745,774, filed on Oct. 15, 2018, and entitled Thermal Regulating Three-Dimensional Insulative Structures and Articles Comprising the Same, the entirety of which is hereby incorporated herein by reference.

FIELD OF THE DISCLOSURE

The present disclosure generally relates to thermally regulating insulation and/or filling material comprising a plurality of assemblages of a blend of a plurality of fibers including phase change fibers, the assemblages forming three-dimensional structures with internal air spaces. The disclosure also relates to articles comprising the insulation or filling, and to methods of making the insulation and/or filling material.

BACKGROUND

Fundamental principles of science are now increasingly employed for the manufacture of innovative textile products. One such principle is phase change, the process of going from one physical state to another, such as from a solid to a liquid and vice versa. Fiber and textiles which have automatic acclimatizing properties have recently attracting more and more attention, which can be achieved by using phase change material (PCM).

Thermal energy storage (TES) is the temporary storage of high or low temperature energy for later use. It bridges the time gap between energy requirements and energy use. Among the various heat storage techniques, latent heat storage is particularly attractive due to its ability to provide a high storage density at nearly isothermal conditions. PCM takes advantage of latent heat that can be stored or released from the material over a narrow temperature range. PCM possesses the ability to change its state with a certain temperature range. These materials absorb energy during a heating process as phase change takes place, and release energy to the environment during a reverse cooling process and phase change. The absorbed or released heat content is the latent heat. In general, PCM can thereby be used as a barrier to heat, since a quantity of latent heat must be absorbed by the PCM before its temperature can rise. Similarly, the PCM may be used a barrier to cold, as a quantity of latent heat must be removed from the PCM before its temperature can begin to drop.

PCM which can convert from solid to liquid state or from liquid to solid state is the most frequently used latent heat storage material, and suitable for the manufacturing of heat-storage and thermo-regulated textiles and clothing. As shown in FIG. 1, these PCMs absorb energy during a heating or melting process at a substantially constant phase change or transition temperature as a solid to liquid phase change takes, and release energy during a cooling or freezing/crystalizing/solidifying process at the substantially constant transition temperature as a liquid to solid phase change takes.

FIG. 2 shows a typical solid-liquid phase transitioning PCM. From an initial solid state at a solid-state temperature, the PCM initially absorbs energy in the form of sensible heat. In contrast to latent heat, sensible energy is the heat released or absorbed by a body or a thermodynamic system during processes that result in a change of the temperature of the system. As shown in FIG. 2, when the PCM absorbs enough energy such that the ambient temperature of the PCM reaches the transition temperature of the PCM, it melts and absorbs large amounts of energy while staying at an almost constant temperature (i.e., the transition temperature)—i.e., latent heat/energy storage. The PCM continues to absorb energy while staying at the transition temperature until all of the PCM is transformed to the liquid phase, from which the PCM absorbs energy in the form of sensible heat, as shown in FIG. 2. In this way, heat is removed from the environment about the PCM and stored while the temperature is maintained at an “optimum” level during the solid to liquid phase change. In the reverse process, when the environmental temperature/energy about the liquid PCM falls to the transition temperature, it solidifies again, releasing/emitting its stored latent heat energy to the environment while staying at the transition temperature until all of the PCM is transformed to the solid phase. Thus, the managed temperature again remains consistent.

As such, during the complete melting process, the temperature of a typical solid-liquid phase transitioning PCM as well as its surrounding area remains nearly constant. The same is true for the solidification (e.g., crystallization) process; during the entire solidification process the temperature of the PCM does not change significantly. The large heat transfer during the melting process as well as the solidification process, without significant temperature change, makes these PCMs interesting as a source of heat storage material in practical textile applications.

However, the insulation effect reached by a PCM is dependent on temperature and time; it takes place only during the phase change and thereby only in the temperature range of the phase change, and terminates when the phase change in all of the PCMs is complete. Since, this type of thermal insulation is temporary; therefore, it can be referred to as dynamic thermal insulation. Also, modes of heat transfer are strongly dependent on the phase of the material involve in the heat transfer processes. For materials that are solid, conduction is the predominate mode of heat transfer. While for liquid materials, convection heat transfer predominates. Unfortunately, typical PCMs have a relatively low heat-conductivity which fails to provide a required or desired heat exchange rate between the PCMs and a surrounding environment (e.g., a user).

Therefore, a need exists for PCM textile insulation and/or filling materials with improved heat storage and transfer performance.

While certain aspects of conventional technologies have been discussed to facilitate disclosure of the inventions, Applicants in no way disclaim these technical aspects, and it is contemplated that the claimed inventions may encompass one or more of the conventional technical aspects discussed herein.

In this specification, where a document, act or item of knowledge is referred to or discussed, this reference or discussion is not an admission that the document, act or item of knowledge or any combination thereof was, at the priority date, publicly available, known to the public, part of common general knowledge, or otherwise constitutes prior art under the applicable statutory provisions; or is known to be relevant to an attempt to solve any problem with which this specification is concerned.

SUMMARY

Briefly, the present disclosure satisfies the need for improved insulation materials and/or fill materials with phase change material (PCM). The present disclosure may address one or more of the problems and deficiencies of the art discussed above. However, it is contemplated that the disclosure may prove useful in addressing other problems and deficiencies in a number of technical areas. Therefore, the claimed inventions should not necessarily be construed as limited to addressing any of the particular problems or deficiencies discussed herein.

Certain embodiments of the presently-disclosed insulation and/or fill materials, articles comprising the materials, and methods for forming the materials have several features, no single one of which is solely responsible for their desirable attributes. Without limiting the scope of the insulation and/or fill materials, articles and methods as defined by the claims that follow, their more prominent features will now be discussed briefly. After considering this discussion, and particularly after reading the section of this specification entitled “Detailed Description,” one will understand how the features of the various embodiments disclosed herein provide a number of advantages over the current state of the art.

In a first aspect, the present disclosure provides insulation or filling material comprising a plurality of discrete assemblages of a blend of a plurality of fibers. The blend of fibers comprises 20 to 80 wt % cellulosic fibers including a phase change material having a fiber size less than or equal to 6 denier, and 20 to 80 wt % synthetic polymeric fibers having a fiber size less than or equal to 6 denier. The cellulosic fibers have specific latent heat of greater than 20 J/g in a temperature range from 15 to 45 degrees Celsius. The assemblages form three-dimensional structures with internal air spaces. The material has at least 0.8 clo/oz/sqyd.

In some embodiments, the cellulosic phase change fibers comprise a cellulose matrix, inclusions within the cellulose matrix comprising one or more nonpolar organic compounds stabilized with at least one hydrophobic thickener, and a barrier material of nanoscale layered particles dispersed in the cellulose matrix. In some such embodiments, the density of the barrier material is greater in a zone extending about the inclusions relative to the mean density of the barrier material in the cellulose matrix. In some embodiments, the one or more nonpolar organic compounds have a melting point of less than 100 degrees Celsius and are selected from the group consisting of hydrocarbons, waxes, beeswaxes, oils, fatty acids, fatty acid esters, stearic anhydrides and long-chain alcohols. In some embodiments, the one or more nonpolar organic compounds comprise stabilized paraffin with a melting point within the range of 28 degrees Celsius to 32 degrees Celsius, and the barrier material comprises nanoscale layered silicates.

In some embodiments, the cellulosic phase change fibers have a specific latent heat greater than or equal to 50 J/g. In some embodiments, the cellulosic phase change fibers have a fiber size within the range of 2-3 denier. In some embodiments, the synthetic polymeric fibers comprise first synthetic polymeric fibers having a fiber size of less than 2 denier. In some such embodiments, the first synthetic polymeric fibers comprise at least one of siliconized fibers and polyester fibers. In some such embodiments, the blend of fibers comprises 10 to 70 wt % the first synthetic polymeric fibers.

In some embodiments, the synthetic polymeric fibers comprise second synthetic polymeric conjugate fibers. In some such embodiments, the second synthetic polymeric fibers comprise at least one of siliconized fibers and polyester fibers. In some such embodiments, the second synthetic polymeric fibers are conjugate crimped fibers. In some such embodiments, the blend of fibers comprises 10 to 70 wt % the second synthetic polymeric fibers.

In some embodiments, at least one of the synthetic polymeric fibers and the cellulosic phase change fibers have a staple fiber length of 20 mm to 40 mm. In some embodiments, the material has a fill power greater than 350 cubic centimeters.

In some embodiments, the three-dimensional structures comprise fiberballs. In some such embodiments, the fiberballs have an average diameter of 3 mm to 10 mm. In some such embodiments, the fiber blend further comprises binder fibers have a bonding temperature lower than a softening temperature of the cellulosic fibers and the synthetic polymeric fibers. In some such embodiments, the material comprises 50 to 95 wt % of a plurality of the fiberballs formed of the fiber blend having an average diameter of 3.0 to 8.0 mm, and 5 to 50 wt % of the fiber blend being adjacent to one or more fiberballs but that do not themselves comprise one or more fiberballs or any portion thereof. In some such embodiments, the fiberballs and the fiber blend adjacent to one or more fiberballs but that do not themselves comprise one or more fiberballs or any portion thereof forms a batting insulation.

In some embodiments, the three-dimensional structures comprise discrete longitudinally elongated floccules, the floccules including a relatively open enlarged medial portion and relatively condensed twisted tail portions extending from opposing ends of the medial portion. In some such embodiments, the longitudinal length of the floccules is within the range of 2 cm to 4.5 cm, the longitudinal length of the medial portion of the floccules is within the range of 0.1 cm to 2 cm, and the longitudinal length of the tail portions of the floccules is within the range of 0.8 cm to 1.8 cm.

In another aspect, the present disclosure provides an article comprising any of the insulation or filling material of the first aspect positioned within a compartment of the article. In some embodiments, the article is selected from the group consisting of an outerwear product, clothing, footwear, headwear, a sleeping bag, bedding and a furniture product.

In another aspect, the present disclosure provides a method of making the insulation or filling material of the first aspect. The method comprises mixing fibers comprising 20 to 80 wt % cellulosic fibers including a phase change material, and 20 to 80 wt % synthetic polymeric fibers. The cellulosic fibers have a fiber size less than 6 denier and a specific latent heat of greater than 20 J/g in a temperature range from 15 to 45 degrees Celsius. The synthetic fibers have a fiber size less than 6 denier. The method also comprises forming a plurality of assemblages from the fiber mixture having a three-dimensional structure with internal air spaces. The insulation or filling material having at least 0.8 clo/oz/sqyd.

In some embodiments, forming the plurality of assemblages from the fiber mixture comprises forming fiberballs from the fiber mixture. In some embodiments, forming the plurality of assemblages from the fiber mixture comprises forming discrete longitudinally elongated floccules from the fiber mixture, the floccules including a relatively open enlarged medial portion and relatively condensed twisted tail portions extending from opposing ends of the medial portion.

These and other features and advantages of this disclosure will become apparent from the following detailed description of the various aspects of the disclosure taken in conjunction with the appended claims and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The subject matter of the disclosure, which is regarded as the inventions, is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other features, aspects, and advantages of the disclosure will be readily understood from the following detailed description taken in conjunction with the accompanying drawings, which are not necessarily drawn to scale, wherein:

FIG. 1 is a schematic illustrating the phase change cycle of a solid-liquid phase transitioning phase change material (PCM).

FIG. 2 is a graph illustrating the temperature and energy content profile of a solid-liquid phase transitioning PCM.

FIG. 3 illustrates a cross-sectional view of a portion of an exemplary PCM fiber according to the present disclosure.

FIG. 4 illustrates an elevational view of insulation and/or filling material formed of fiberballs according to the present disclosure.

FIG. 5 illustrates an elevational view of a fiberball of the insulation and/or filling material of FIG. 4.

FIG. 6 illustrates a side view of a fiberball of the insulation and/or filling material of FIG. 4.

FIG. 7 illustrates an elevational view of a floccule of insulation and/or filling material according to the present disclosure.

FIG. 8 illustrates a top view of the floccule of FIG. 7.

FIG. 9 illustrates a side view of the floccule of FIG. 7.

FIG. 10 illustrates an enlarged view of a portion of a three-dimensional assemblage of fibers of the insulation and/or filling material according to the present disclosure.

FIG. 11 illustrates an exemplary solid-liquid phase transitioning PCM transitioning from a solid phase to a liquid phase.

FIG. 12 is a thermal image of a user's hand illustrating the temperature thereof.

FIG. 13 is a thermal image of an example of insulation and/or filling material according to the present disclosure prior to exposure to the user's hand of FIG. 12.

FIG. 14 is a thermal image of the exemplary insulation and/or filling material of FIG. 13 subsequent to exposure to the user's hand of FIG. 12.

DETAILED DESCRIPTION

Aspects of the present disclosure and certain features, advantages, and details thereof, are explained more fully below with reference to the non-limiting embodiments illustrated in the accompanying drawings. Descriptions of well-known materials, fabrication tools, processing techniques, etc., are omitted so as to not unnecessarily obscure the disclosure in detail. It should be understood, however, that the detailed description and the specific example(s), while indicating embodiments of the disclosure, are given by way of illustration only, and are not by way of limitation. Various substitutions, modifications, additions and/or arrangements within the spirit and/or scope of the underlying inventive concepts will be apparent to those skilled in the art from this disclosure.

In one aspect, the disclosure provides insulation and/or filling material comprising a plurality of assemblages of a blend of a plurality of fibers. The blend of fibers comprises 20 to 80 wt % cellulosic fibers that include a phase change material (PCM) and 20 to 80 wt % synthetic polymeric fibers. The cellulosic fibers have a fiber size less than or equal to 6 denier and a specific latent heat of greater than 20 J/g in a temperature range from 15 to 45 degrees Celsius, and the synthetic polymeric fibers having a fiber size less than or equal to 6 denier. The assemblages comprise three-dimensional structures that form internal air spaces. The insulation or filling material has at least 0.8 clo/oz/sqyd. In some embodiments, the insulation or filling material may have at least 0.9 clo/oz/sqyd, or at least 1 clo/oz/sqyd.

The insulation or filling material has a fill power greater than 350 cubic centimeters. In some embodiments, the insulation or filling material may have a fill power greater than 375 cubic centimeters, or greater than 400 cubic centimeters. Fill power is a measure of loft or “fluffiness.” The higher the fill power, the more air an ounce of the down can trap, and thus the more insulating ability an ounce of the down will have. Technically speaking, fill power is a measurement of the amount of space one ounce of down will occupy in cubic inches when allowed to reach its maximum loft. For example, one ounce of 550 fill power down will loft to 550 cubic inches.

The synthetic polymeric fibers may comprise 20 to 80 wt % of the fiber mixture of the insulation and/or filling material, including any and all ranges and subranges therein. For example, in some embodiments, the fiber mixture of the insulation and/or filling material (and thereby the insulation and/or filling material itself) comprises 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79 or 80 wt % of the blend of fibers, including any and all ranges and subranges therein (e.g., 30 to 80 wt %, 40 to 80 wt %, 50 to 80 wt, 60 to 80 wt % or 65 to 75 wt %). In one exemplary embodiment, the synthetic polymeric fibers comprise 70 wt % of the fiber blend of the insulation and/or filling material.

In some embodiments, the synthetic fibers of the blend of fibers may include differing synthetic fibers (i.e., synthetic polymeric fibers that differ in some metric, such as composition, denier, length, coating(s), shape/crimp, etc.). For example, in one exemplary embodiment the synthetic fibers of the blend of fibers include first synthetic polymeric fibers and second synthetic polymeric fibers. In such embodiments, the first synthetic polymeric fibers may comprise 10 to 70 wt % of the blend of fibers, including any and all ranges and subranges therein. For example, in some embodiments, the first synthetic polymeric fibers comprises 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69 or 70 wt % of the blend of fibers, including any and all ranges and subranges therein (e.g., 10 to 50 wt % or 20 to 40 wt %). In such embodiments, the second synthetic polymeric fibers may comprise 10 to 70 wt % of the blend of fibers, including any and all ranges and subranges therein. For example, in some embodiments, the second synthetic polymeric fibers comprises 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69 or 70 wt % of the blend of fibers, including any and all ranges and subranges therein (e.g., 10 to 50 wt % or 20 to 40 wt %).

Many synthetic fibers are known in the art, and any desired synthetic fibers may be used in the disclosed insulation and filling material. Indeed, different fibers have different properties, and lend themselves toward advantageous uses in different applications. This information is well within the purview of persons having ordinary skill in the art. While a wide array of synthetic fibers may be used in the disclosed insulation and filling material, in some embodiments, the synthetic fibers are selected from the group consisting of polyamide, polyester, acrylic, acetate, polyolefin, nylon, rayon, lyocell, aramid, spandex, viscose, and modal fibers, and combinations thereof.

In particular embodiments, the synthetic fibers (e.g., the first and/or second synthetic polymeric fibers) comprise polyester fibers. In some embodiments, such polyester fibers comprise one or more of poly(ethylene terephthalate), poly(hexahydro-p-xylylene terephthalate), poly(butylene terephthalate), poly-1,4-cyclohexelyne dimethylene (PCDT) and terephthalate copolyesters in which at least 85 mole percent of the ester units are ethylene terephthalate or hexahydro-p-xylylene terephthalate units. In a particular embodiment, the synthetic fibers synthetic polymeric fibers are polyethylene terephthalate fibers.

Denier is a unit of measure defined as the weight in grams of 9000 meters of a fiber or yarn. It is a common way to specify the weight (or size) of the fiber or yarn. For example, polyester fibers that are 1.0 denier typically have a diameter of approximately 10 micrometers. Micro-denier fibers are those having a denier of 1.0 or less, while macro-denier fibers have a denier greater than 1.0.

The synthetic fibers have a denier of less than or equal to 6 denier, including any and all ranges and subranges therein. For example, in some embodiments, the denier of the synthetic fibers is 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9 or 6.0, including any and all ranges and subranges therein (e.g., less than or equal to 2 denier, 1.0 to 2.0 denier, 5.0 to 6.0 denier, etc.).

In some embodiments, the synthetic fibers of the blend of fibers may include synthetic fibers of differing deniers. For example, the first synthetic polymeric fibers of the synthetic polymeric fibers of the blend of the fibers may include synthetic polymeric fibers less than or equal to 2.0 denier, including any and all ranges and subranges therein. For example, in some embodiments, the denier of the first synthetic polymeric fibers is 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9 or 2.0, including any and all ranges and subranges therein (e.g., 1.0 to 2.0 denier, 1.3 to 1.7 denier, etc.). In one embodiment, the denier of the first synthetic polymeric fibers is 1.5 denier. As another example, the second synthetic polymeric fibers of the synthetic polymeric fibers of the blend of the fibers may include synthetic polymeric fibers less than or equal to 6.0 denier, including any and all ranges and subranges therein. For example, in some embodiments, the denier of the second synthetic polymeric fibers is 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9 or 2.0, including any and all ranges and subranges therein (e.g., less than or equal to 2.0 denier, 1.0 to 3.0 denier, 1.5 to 1.2 denier, etc.). In one embodiment, the denier of the second synthetic polymeric fibers is 2 denier.

The synthetic fibers include a staple length within the range of 15 mm to 60 mm, such as a length of 18 mm to 51 mm, or 20 mm and 40 mm, including any and all ranges and subranges therein. For example, in some embodiments, the length of the synthetic fibers may be 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59 or 60 mm, including all ranges/subranges therein (e.g., 20 to 40 mm, 25 to 35 mm, etc.). In some embodiments, the synthetic fibers of the blend of fibers may include synthetic fibers of differing lengths. In some other embodiments, the synthetic fibers of the blend of fibers may include synthetic fibers of the same lengths (or approximately the same lengths).

In some embodiments, the synthetic fibers are siliconized. The term “siliconized” means that the fiber is coated with a silicon-comprising composition (e.g., a silicone). Siliconization techniques are well known in the art, and are described, for example, in U.S. Pat. No. 3,454,422. The silicon-comprising composition may be applied using any method known in the art, e.g., spraying, mixing, dipping, padding, etc. The silicon-comprising (e.g., silicone) composition, which may include an organosiloxane or polysiloxane, bonds to an exterior portion of the fiber. In some embodiments, the silicone coating is a polysiloxane such as a methylhydrogenpolysiloxane, modified methylhydrogenpolysiloxane, polydimethylsiloxane, or amino modified dimethylpolysiloxane. As is known in the art, the silicon-comprising composition may be applied directly to the fiber, or may be diluted with a solvent as a solution or emulsion, e.g. an aqueous emulsion of a polysiloxane, prior to application. Following treatment, the coating may be dried and/or cured. As is known in the art, a catalyst may be used to accelerate the curing of the silicon-comprising composition (e.g., polysiloxane containing Si—H bonds) and, for convenience, may be added to a silicon-comprising composition emulsion, with the resultant combination being used to treat the synthetic fiber. Suitable catalysts include iron, cobalt, manganese, lead, zinc, and tin salts of carboxylic acids such as acetates, octanoates, naphthenates and oleates. In some embodiments, following siliconization, the fiber may be dried to remove residual solvent and then optionally heated to between 65 and 200 degrees Celsius to cure.

In some embodiments, the synthetic fibers of the blend of fibers may include non-siliconized fibers and non-siliconized fibers. For example, the first synthetic polymeric fibers of the synthetic fibers of the blend of the fibers may be siliconized fibers and the second synthetic polymeric fibers may be non-siliconized fibers, or vice versa. In some other embodiments, the synthetic fibers of the blend of fibers may include only non-siliconized fibers (e.g., both the first and synthetic polymeric fibers may be non-siliconized fibers) or only siliconized fibers (e.g., both the first and synthetic polymeric fibers may be siliconized fibers).

In some embodiments, at least some of the synthetic fibers are slickened with a slickening agent, e.g., segmented copolymers of polyalkyleneoxide and other polymers, such as polyester, or polyethylene or polyalkylene polymers as is mentioned in U.S. Pat. No. 6,492,020.

In some embodiments, the synthetic fibers may be crimped fibers. Various crimps, including spiral (or helical) and standard crimp, are known in the art. If the synthetic fibers include a crimp, the fiber may typically have any crimp. However, in some embodiments, the fibers are not spirally or helically crimped fibers. In some embodiments, at least some of the synthetic fibers comprise conjugate fibers (multiple-component fibers with a specific ability to crimp via a heat treatment). For example, at least some of the synthetic fibers comprise solid conjugate fibers and/or hollow conjugate fibers. In some embodiments, the synthetic fibers are not crimped. In some embodiments, the first synthetic polymeric fibers are crimped fibers, and the second synthetic polymeric fibers are non-crimped fibers, or vice versa. In some other embodiments, the synthetic fibers of the blend of fibers may include only crimped fibers (e.g., both the first and synthetic polymeric fibers are crimped) or only non-crimped fibers (e.g., both the first and synthetic polymeric fibers are non-crimped fibers).

As noted above, the fiber mixture of the insulation and/or filling material (and thereby the insulation and/or filling material itself), includes 20 to 80 wt %, including any and all ranges and subranges therein, cellulosic fibers including a phase change material. For example, in some embodiments, the fiber mixture of the insulation and/or filling material (and thereby the insulation and/or filling material itself) comprises 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79 or 80 wt % of the blend of fibers, including any and all ranges and subranges therein (e.g., 10 to 50 wt %, 15 to 15 wt %, 20 to 40 wt % or 25 to 35 wt %). In one exemplary embodiment, the cellulosic fibers comprise 30 wt % of the fiber blend of the insulation and/or filling material.

The denier of the cellulosic fibers may be the same as or different than the denier of at least some of the synthetic fibers. In some embodiments, the denier of the cellulosic fibers may be less than or equal to 6 denier, including any and all ranges and subranges therein. For example, in some embodiments, the denier of the cellulosic fibers is 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9 or 6.0, including any and all ranges and subranges therein (e.g., 1.0 to 3.0 denier, 5.0 to 6.0 denier, 3 denier, 6 denier, etc.). In some embodiments, at least some of the cellulosic fibers may be 6 denier (e.g., 6.7 dtex). In some embodiments, at least some of the cellulosic fibers may be 2 denier (e.g., 3.2 dtex).

The cellulosic fibers include a staple length within the range of 10 mm to 60 mm, such as a length within the range of 10 mm to 30 mm, including any and all ranges and subranges therein. For example, in some embodiments, the length of the cellulosic fibers may be 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59 or 60 mm, including all ranges/subranges therein (e.g., 10 mm to 30 mm, 15 to 25 mm, etc.). In one embodiment, the cellulosic fibers are 20 mm in length. In some embodiments, the cellulosic fibers of the blend of fibers may include cellulosic fibers of differing lengths, or may all be of the same length.

The cellulosic fibers with the phase change material may include a specific latent heat (i.e., energy absorption) of greater than 20 J/g, such as within a temperature range from 15 to 45 degrees Celsius. In some embodiments, the cellulosic fibers may include a specific latent heat of greater than 50 J/g, such as within in a temperature range from 15 to 45 degrees Celsius. In such embodiments, the cellulosic fibers may be 2 denier. In some embodiments, the cellulosic fibers may include a specific latent heat of greater than 90 J/g, such as within in a temperature range from 15 to 45 degrees Celsius. In such embodiments, the cellulosic fibers may be 6 denier.

As noted above, phase change materials are able change state at nearly constant temperature, and thereby store a relatively large quantity of energy. The cellulosic fibers may utilize the thermal energy storage of a liquid-solid phase change material with a melting/solidification (or crystallization) point (i.e., transition temperature) within the range of 15 to 45 degrees Celsius, or more preferably 15 to 35 Celsius. In one embodiment, the phase change material cellulosic fibers may include a melting/solidification point with the range of 28 to 32 degrees Celsius.

Many synthetic liquid-solid phase change materials are known in the art, and any desired a liquid-solid phase change material may be utilized with the cellulosic fibers. Different liquid-solid phase change materials have different properties (e.g., phase change temperatures/ranges and heat storage capacities), and lend themselves toward advantageous uses in different applications. This information is well within the purview of persons having ordinary skill in the art. While a wide array of liquid-solid phase change material may be used in the cellulosic fibers, in some embodiments, the liquid-solid phase change material is selected from the group consisting of hydrated inorganic salt, linear long chain hydrocarbons, polyethylene glycol (PEG) (e.g., paraffin wax), fatty acids (capric, lauric, palmitic and stearic acids) and their binary mixtures, for example.

The phase change material may be configured or chosen for use in fiber as a relatively high efficiency cooling system with thermal energy system (TES) with at least one of the following characteristics: (i) a melting/solidification point between 15 and 35 degrees Celsius; (ii) little temperature difference between the melting point and the solidification point; (iii) environment friendly; (iv) low toxicity; (v) relatively non-flammable; (vi) stability for repetition of melting and solidification; (vii) relatively large thermal conductivity, for effective heat transfer; (viii) ease of availability; and (ix) relatively low price. A wide spectrum of phase change material is available with different heat storage capacity and phase change temperature. In some embodiments, the liquid-solid phase change material is at least one of a hydrocarbon, wax, beeswax, oil, fatty acid, fatty acid ester, stearic anhydride and long-chain alcohol.

The liquid-solid phase change material may be incorporated into the cellulosic fibers in any number of ways. For example, the phase change material may be microencapsulated. The microencapsulated phase change material can be incorporated into the base fiber material prior to formation (e.g., dry spinning, wet spinning, extraction, etc.), or the microencapsulated phase change material can be attached to the formed fibers. As another example, the phase change material may be applied as a coating to the formed fibers. As another example, the phase change material may be incorporated into a film and laminated to the fibers.

In one embodiments, the liquid-solid phase change material may be incorporated into the base material of the cellulosic fibers and co-extruded with the base material during formation of the fiber. In some embodiments, the cellulosic fibers may be base lyocell (ALCERU) based fibers with the liquid-solid phase change material incorporated therein. For example, cellulosic fibers may be cellulose fibers made from dissolving pulp (e.g., bleached wood pulp) using dry jet-wet spinning. The liquid-solid phase change material may be incorporated into the pulp prior to extrusion. In one such cellulosic fiber embodiment, the liquid-solid phase change material may be paraffin which is embedded in crystalline and tear resistant functional lyocell fibers. The portions of phase change material within the fibers may form many micro composite accumulators per unit of the cellulosic fiber. In one embodiment, the cellulose fiber with thermoregulating properties produced according to the lyocell-process may be comprised of greater than 56% cellulose, about 19-39% (e.g., about 29%) stabilized paraffin as the phase change material, and 4-5% organically modified mineral (e.g., layered silicate).

In some embodiments, the cellulosic fibers may be lyocell based fibers with paraffin as the liquid-solid phase change material and lipophilic substances incorporated into the fibers. The cellulosic fibers may thereby not include the paraffin in microcapsule form or as a coating. For example, as shown in the partial cross-sectional view illustrated in FIG. 3 in some embodiments the cellulosic fibers may include a cellulose matrix 2 with inclusions 3 dispersed therein. The inclusions 3 may comprise one or more nonpolar organic compounds as the phase change material, which are stabilized with at least one hydrophobic thickener. In one such embodiment, the nonpolar organic compounds may have a melting point of less than 100 degrees Celsius, and/or may be selected from the group consisting of hydrocarbons, waxes, beeswaxes, oils, fatty acids, fatty acid esters, stearic anhydrides and long-chain alcohols. For example, the nonpolar organic compounds may comprise stabilized paraffin with a melting point with the range of 28 degrees Celsius to 32 degrees Celsius.

As shown in FIG. 3, a barrier material 4 of nanoscale layered particles may be dispersed in the cellulose matrix 2. In particular, the layered particles may be presented separately or exfoliated in the cellulose matrix 2, as shown in FIG. 3. As also shown in FIG. 3, around the inclusions 3, the density of the barrier material 4 may be increased relative to its mean density in the cellulose matrix 2. Accordingly, the inclusions 3 may be surrounded by a zone of the barrier material, through which the nonpolar organic compounds and optionally active ingredients present therein are only able to enter the cellulose matrix 2 via tortuous paths, if at all. Through suitable selection and dosage of the barrier material 4, the permeability for active ingredients can be adjusted in a targeted manner (“controlled release system”). In a temperature range from 15 to 45 degrees Celsius, the cellulosic fibers may have a specific latent heat of greater than 20 J/g, or greater than 30 J/g, or greater than 50 J/g.

In one embodiment, the cellulosic fibers may be a fiber disclosed in U.S. Pat. No. 9,303,335 to Kolbe et al., which is incorporated herein by reference in its entirety. For example, the cellulosic fibers may be fibers sold under the tradename Clima by Cell Solution ApS, Smartpolymer GmbH and/or Smartpolymer GmbH. Similarly, the cellulosic fibers may be formed according to a process disclosed in in U.S. Pat. No. 9,303,335 to Kolbe et al. For example, the cellulosic fibers may be formed from an emulsion with at least one nonpolar organic compound in a solution of cellulose in a solvent, which may be prepared and stabilized by adding at least one hydrophobic viscosity-increasing agent and/or nanoscale, sheet-like and/or elongated, hydro-phobicized particles (e.g., sheet silicates, nanotubes or nanofilaments) to the emulsion. The at least one hydrophobic viscosity-increasing agent and/or hydro-phobicized particles may surround droplet-like inclusions of the nonpolar organic compound(s) and form a suspension. The cellulose may then be recrystallized to form a fiber with a cellulose matrix in which the nonpolar organic compound(s) is/are incorporated in disperse form.

As discussed above, the blend of the plurality of fibers may be formed into a plurality of discrete assemblages that form three-dimensional structures disclosed herein that form internal air spaces 22 between the fibers, as shown in FIG. 10. The internal air spaces 22 may be in communication with openings or spaces between the fibers at the exterior of the assemblages. As such, the internal air spaces 22 may be in communication with the air or environment about or adjacent to the assemblages. However, the internal air spaces 22 may also be relatively trapped or isolated within the interior of the three-dimensional structures by the fibers 20, as shown in FIG. 10. The internal air spaces 22 may thereby be formed, and isolated within the three-dimensional structures, by the arrangement of the fibers 20. For example, air may need to travel along a substantially circuitous path through a three-dimensional structure disclosed herein that extends over, around and/or past a plurality or numerous portions of fiber(s) 20 that form the three-dimensional structure to reach a particular air space 22 located within (e.g., relatively deeply within) the three-dimensional structure. As such, the particular air space 22 is not readily accessible (e.g., via convection). The three-dimensional structures (e.g., fiberballs and at least the medial portion of floccules disclosed herein) form a relatively greater amount of internal trapped air spaces 22 as compared to other forms of insulation and filling materials, such as batted insulations and filling materials for example. The three-dimensional structures (e.g., the fiberballs and at least the medial portion of floccules disclosed herein) thereby form a relatively greater amount of internal trapped air spaces 22 near, adjacent, about the fibers 20 of the fiber blend (including the fibers with phase change material) as compared to other forms of insulation and filling materials (e.g., traditional layered batting insulation constructs). The internal trapped air spaces 22 of the three-dimensional structures (e.g., the fiberballs and floccules disclosed herein) provide increased depth and insulative capability as compared to other forms of insulation and filling materials (e.g., traditional layered batting insulation constructs).

In some embodiments, the plurality of fibers of the fiber blend forming the assemblages may be entangled and not bonded together. In some other embodiments, the plurality of fibers of the fiber blend forming the assemblages may be entangled and bonded together. In some embodiments, the plurality of fibers of the fiber blend forming the assemblages may be randomly or non-uniformly or similarly entangled. In some other embodiments, the plurality of fibers of the fiber blend forming the assemblages may be specifically, deliberately, substantially uniformly or similarly entangled.

As shown in FIGS. 4-6, in some embodiments the three-dimensional structures formed by the discrete assemblages comprises fiberballs 5. The fiberballs 5 resemble “balls” of assemblages of fibers of the fiber blend. As shown in FIGS. 4-6, the fiberballs 5 may form a relatively or generally spherical shape, relatively or generally ellipsoidal shape, or relatively or generally any other regular or irregular three-dimensional form/shape. The plurality of fibers of the fiber blend forming the fiberballs 5 may be randomly entangled. For example, the fiberballs 5 may be a substantially round random entanglement the fiber blend fibers (which may not be bonded to each other).

Any known formation process that is conducive to forming fiberballs from the fiber blend (knowledge well within the purview of a skilled artisan in the field) may be used. For example, methods of forming fiberballs are described, for example, in U.S. Pat. Nos. 4,794,038 and 6,613,431, which are expressly incorporated herein by reference in their entireties. While any fiberball formation techniques may be used, in some embodiments, the fiberballs are formed by air-tumbling small tufts of the synthetic and binder fibers repeatedly against a wall of a vessel so as to densify the bodies and make them rounder, thereby forming fiberballs. In other embodiments, a fiber ball machine is used to form fiberballs. In some embodiments, the fiberballs are formed using a ball card (i.e., a carding machine modified for production of fiberballs).

In some embodiments, prior to fiberball formation, the synthetic fibers, and/or the binder fibers are opened. As is well known in the art, opening entails separating the fibers to some extent (e.g., using an opener, such as a bale opening system) prior to further processing.

The fiberballs 5 may define an average diameter (e.g., average maximum diameter) of 3.0 to 10.0 mm (e.g., 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, 6.0, 6.1, 6.2, 6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9, 7.0, 7.1, 7.2, 7.3, 7.4, 7.5, 7.6, 7.7, 7.8, 7.9, 8.0, 8.1, 8.2, 8.3, 8.4, 8.5, 8.6, 8.7, 8.8, 8.9, 9.0, 9.1, 9.2, 9.3, 9.4, 9.5, 9.6, 9.7, 9.8, 9.9 or 10 mm), including any and all ranges and subranges therein (e.g., 4 to 10 mm, 5 to 10 mm, 5 to 9 mm, 6 to 9, 6 to 8 mm, etc.).

As shown in FIGS. 7-9, in some embodiments the three-dimensional structures formed by the discrete assemblages comprises longitudinally elongated floccules 6 having a relatively open enlarged medial portion 7 and relatively condensed twisted tail portions 8 extending from opposing ends of the medial portion 7. Generally, the floccules 6 are a collection of the blend of fibers that are formed into an elongate structure with an expanded, loose medial portion 7 and slender, tight, twisted tail portions 8 extending from opposing ends of the medial portion 7. In some embodiments, the floccules 6 comprise a floccule disclosed in International PCT Patent Publication No. WO2017/058986, which is expressly incorporated herein by reference in its entirety.

As shown in FIGS. 7-9, the medial portion 6 is “open” such that the fibers are loosely arranged or substantially spaced from one another. In this way, the density of the fibers within the medial portion 6 is less than that of the tail portions 7. The fibers of the tail portions 7 may formed into a relatively slender, closed, twisted arrangement. The tail portions 7 may be slender in that their width and/or thickness may be substantially less than that of the medial portion 6. The tail portions 7 may define a substantially circular cross-sectional shape or any non-circular shape that may or may not differ from a cross-sectional shape of the medial portion 6.

The fibers of the tail portions 7 may be bundled or pulled together into a relatively tight or close relationship and arranged in a twisted or spiraling arrangement with each other as a whole, as shown in FIGS. 7-9. In this way, the tail portions 7 may become smaller in cross-sectional size as the fibers extending from the medial portion 6 and are pulled/twisted together, as a whole, into the relatively tight closed twisted nature, as shown in FIGS. 7-9. The tail portions 7 may thereby include a substantially “closed” nature (e.g., as compared to the medial portion 6), as shown in FIGS. 7-9, with a fiber density greater than that of the medial portion 6.

The fibers of the fiber blend forming the floccules 10 may be staggered along their length (i.e., the fibers may not be aligned along the longitudinal direction and extend the entire longitudinal length L3 of the floccules 10). For example, a particular fiber 20 may partially form both the medial portion 6 and at least one of the tail portions 7, or may only partially form a portion of the floccule 6.

The medial portion 6 and the tail portions 7 may include about the amount of fibers, or the medial portion 6 and the tail portions 7 may include a differing amount of fibers. For example, a particular medial portion 6 may include more fibers than at least one of the corresponding the tail portions 7. Similarly, the tail portions 7 of a floccule 6 may include a different amount of fibers with respect to each other. In some embodiments, the length L2, width, thickness, shape, arrangement or any other configuration of one of the tail portions 7 of a particular floccule 6 may differ from the other tail portion 7 thereof. The total number of discreet or individual fibers per floccule 6 may vary, such as due to the particular configuration or composition of the fibers being used. In some embodiments, the floccules 10 may include a total number of fibers within the range of about 600 total fibers to about 1,200 total fibers.

As shown in FIGS. 7-9, the tail portions 7 may define opposing free ends that define the longitudinal ends of the floccules 10. The medial 12 and tail 14 portions, and thereby a floccule 6 as a whole, may be substantially elongated along a longitudinal direction. In some embodiments, the medial 12 and tail 14 portions may be substantially aligned along the longitudinal direction. The medial 12 and/or tail 14 portions may extend substantially linearly along the longitudinal direction. In some alternative embodiments (not shown), the medial 12 and/or tail 14 portions may be arcuate or curved such that the floccule 6, as a whole, forms a convex or concave shape.

As also shown in FIGS. 7-9, the medial portion 6 of the floccule 6 may extend longer in the longitudinal direction than each of the tail portions 7. While the transition between the medial portion 6 and the tail portions 7 may be gradual, for purposes of this disclosure the tail portions 12 of the floccules 10 are defined as the portions in which the majority of fibers are arranged in a twisted or spiraling arrangement with each other as a whole. As indicated in FIG. 8, the medial portion 6 may define a maximum longitudinal length L1 that is greater than the maximum longitudinal length L2 of the tail portions 7. However, in some floccules 10 the length L1 of the medial portion is equal to or less than the length L2 of at least one of the corresponding tail portions 7. The lengths L2 the tail portions 7 of a particular floccule 6 may be substantially the same or may differ from each other. In some embodiments, the length L1 of the medial portion may be within the range of about 0.1 cm to about 2 cm, or within the range of about 1 cm to about 1.8 cm. In some embodiments, the length L2 of the tail portion 7 may be within the range of about 0.8 cm to about 1.8 cm, or within the range of about 1 cm to about 1.5 cm. The total length longitudinal length L3 of a floccule 6 extending between free ends of the tail portion 7 may be within the range of about 2 cm to about 4.5 cm, or about 2.5 cm to about 4 cm. In some embodiments, blowable insulation or filling material formed of a plurality of floccules 10 may include an average total floccule length L3 of about 3.5 cm, an average tail portion 12 length L2 of about 1.1 cm, and/or an average medial portion 6 length L2 of about 1.2 cm. In some embodiments, the longitudinal length L3 of the floccules is within the range of 2 cm to 4.5 cm, the longitudinal length L1 of the medial portion 7 of the floccules 6 is within the range of 0.1 cm to 2 cm, and the longitudinal length L2 of the tail portions 8 of the floccules 6 is within the range of 0.8 cm to 1.8 cm.

In some embodiments, the medial portion 6 may define a maximum width and a maximum thickness of the floccules 6. The width of the medial portion 6 of the floccules 6 may be larger than the thickness thereof. The medial portion 6 may thereby substantially form an oval or ellipse shape in cross-section. In some embodiments, the cross-sectional shape of the medial portion 6 may be substantially rounded elliptical or substantially pointed elliptical. In other embodiments, the width of the medial portion 6 may be equal to or less than the thickness thereof. In some embodiments, the width of the medial portion 6 may be within the range of about 0.2 cm to about 1 cm.

The floccules 6 may be manufactured via any process. For example, methods of forming floccules 6 are described, for example, International PCT Patent Publication No. WO2017/058986. In one embodiment, the floccules 6 may be formed by rotating a hollow drum including a plurality of apertures extending therethrough within the range of 100 RPM to 400 RPM, and forming a vacuum pressure within an interior of the rotating drum. The blend of fibers, as staple fibers, may be applied to an exterior surface of the rotating drum such that the internal vacuum pulls a plurality of the fibers through a plurality of the apertures to partially form a plurality of floccules. The partially-formed floccules may be retained within the rotating drum for a dwell time within the range of 2 minutes to 5 minutes to form a plurality of the discrete, longitudinally elongated floccules 6 each including the relatively open enlarged medial portion 7 and the relatively condensed twisted tail portions 8 extending from opposing ends of the medial portion 7.

In some embodiments, the insulation or filling material may be formed as a loose or unbonded plurality of the discrete assemblages of the blend of fibers. In some such embodiment, the insulation or filling material may include loose fibers that do not form the discrete assemblages. The loose fibers may or may not be fiber of the blend of fibers.

In some other embodiments, the insulation or filling material may be formed as batting insulation of the discrete assemblages of the blend of fibers being bonded together. For example, the insulation or filling material may comprise a nonwoven web formed of the discrete assemblages of the blend of fibers being bonded together via binder fibers. In some embodiments, structurally, the nonwoven web may include 50 to 95 wt % the discrete assemblages of the blend of fibers (e.g., the fiberballs 5 and/or the floccules 6), and 5 to 50 wt % of a plurality of portions of the nonwoven web that are adjacent to one or more of the discrete assemblages but that do not themselves comprise one or more of the discrete assemblages or any portion thereof. The binder fibers may include a denier within the range of 1.0 to 5.0, and/or and a length within the range of 18 mm to 71 mm. The binder fibers have a bonding temperature lower than the softening temperature of the blend of fibers forming the assemblages (i.e., the synthetic fibers and the cellulosic fibers). The plurality of portions of the nonwoven web that are adjacent to the one or more assemblages but that do not themselves comprise one or more of the assemblages or any portion thereof may comprise the blend of fibers, or may not include the blend of fibers. Similarly, the assemblages may comprise the binder fibers, or may not include the binder fibers.

The batting may be heat treated so as melt all or a portion of the binder fibers, thereby forming a bonded web-type batting. Accordingly, persons having ordinary skill in the art will understand that, in such embodiments, although “binder fibers” are recited in the fiber mixture of the nonwoven web, said fibers will be wholly or partially melted fibers, as opposed to binder fibers in their original, pre-heat treatment form. Nevertheless, as used herein, denier and length descriptions of the binder fibers describe characteristics of the binder fibers prior to thermal bonding treatment.

Binder fibers are well known in the art, and an array of binder fibers are commercially available. The binder fibers may be conventional binder fibers (e.g., low-melt polyester binder fibers), or other binder fibers, provided that whatever binder fiber is used, the binder fiber has a bonding temperature lower than the softening temperature of the synthetic and cellulosic fibers. Binder fibers are discussed, for example, in U.S. Pat. No. 4,794,038, and general protocols for certain embodiments of binder fibers are set forth in U.S. Pat. No. 4,281,042 and in U.S. Pat. No. 4,304,817. In some embodiments, the binder fibers are mono-component fibers. In some components, the binder fibers are multicomponent fibers (e.g., bicomponent fibers, for example, sheath-core fibers, where the core comprises a higher melting component than the sheath). In some embodiments, the binder fibers comprise blends of one or more different types of binder fibers.

The fiber mixture of the batting may comprise 5 to 40 wt % of the binder fibers, including any and all ranges and subranges therein. For example, in some embodiments, the batting comprises 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, or 40 wt % of the binder fibers, including any and all ranges and subranges therein (e.g., 10 to 25 wt %).

The binder fibers may have a denier of 1.0 to 5.0, including any and all ranges and subranges therein. For example, in some embodiments, the denier is 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, or 5.0 denier, including any ranges/subranges therein (e.g., 1.5 to 3.5 denier, 1.9 to 2.5 denier, etc.).

The binder fibers may have a length of 18 mm to 71 mm, including any and all ranges and subranges therein. For example, in some embodiments, the length is 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62 ,63, 64, 65, 66, 67, 68, 69, 70, or 71 mm, including all ranges/subranges therein (e.g., 18 to 51 mm, 40 to 60 mm, etc.).

As indicated above, the binder fibers may have a bonding temperature lower than the softening temperature of the synthetic and cellulosic fibers. In some embodiments, the binder fibers have a bonding temperature of less than or equal to 200° C. In some embodiments, the binder fibers have a bonding temperature of 50 to 200, including any and all ranges and subranges therein. In some embodiments, the binder fibers have a bonding temperature of 80° C. to 150° C. In some embodiments, the binder fibers have a bonding temperature of 100° C. to 125° C.

In some embodiments, the binder fibers have a melting temperature that is 15 to 170 degrees Celsius less than the melting temperature of the synthetic and cellulosic fibers. For example, in some embodiments, the binder fibers have a melting temperature that is 15-170° C. less than the melting temperature of the synthetic fibers (e.g., 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 100, 101, 102, 103, 104, 105, 106, 107, 108, 109, 110, 111, 112, 113, 114, 115, 116, 117, 118, 119, 120, 121, 122, 123, 124, 125, 126, 127, 128, 129, 130, 131, 132, 133, 134, 135, 136, 137, 138, 139, 140, 141, 142, 143, 144, 145, 146, 147, 148, 149, 150, 151, 152, 153, 154, 155, 156, 157, 158, 159, 160, 161, 162, 163, 164, 165, 166, 167, 168, 169, or 170° C., including any and all ranges and subranges therein. For example, in some embodiments, the synthetic and/or cellulosic fibers have a melting point of about 250° C. or greater, and the binder fibers may have a melting point of 80 to 180° C. (e.g., about 110° C.).

In some embodiments, the binder fibers comprise low-melt polyester fibers. In some embodiments, the binder fibers are bicomponent fibers comprising a sheath and a core, wherein the sheath comprises a material having a lower melting point than the core. In some embodiments, the binder fibers are polyethylene/polypropylene bicomponent fibers.

In some embodiments, the fiber mixture additionally comprises one or more types of natural fibers in addition to the synthetic fibers and binder fibers. For example, in some embodiments, the fiber mixture additionally comprises one or more members selected from wool, cotton, tencel, flax, animal hair, silk, and down.

The nonwoven web comprises 50 to 90 wt % of the discrete assemblages (e.g., the fiberballs 5 and/or the floccules 6), including any and all ranges and subranges therein; and 10 to 50 wt % of the spaces, including any and all ranges and subranges therein. For example, in some embodiments, the batting/nonwoven web comprises 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, or 90 wt % assemblages, including any and all ranges/subranges therein (e.g., 70 to 90 wt %). In some embodiments, the batting/nonwoven web comprises 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, or 50 wt % spaces, including ranges/subranges therein (e.g., 10 to 30 wt %).

In some embodiments, the batting has a thickness of less than or equal to 40 mm, for example, 5 to 40 mm (e.g., 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, or 40 mm), including all ranges and subranges therein.

The batting has a density of 2 to 12 kg/m3 (e.g., 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, 6.0, 6.1, 6.2, 6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9, 7.0, 7.1, 7.2, 7.3, 7.4, 7.5, 7.6, 7.7, 7.8, 7.9, 8.0, 8.1, 8.2, 8.3, 8.4, 8.5, 8.6, 8.7, 8.8, 8.9, 9.0, 9.1, 9.2, 9.3, 9.4, 9.5, 9.6, 9.7, 9.8, 9.9, 10.0, 10.1, 10.2, 10.3, 10.4, 10.5, 10.6, 10.7, 10.8, 10.9, 11.0, 11.1, 11.2, 11.3, 11.4, 11.5, 11.6, 11.7, 11.8, 11.9, or 12.0 kg/m3), including any and all ranges and subranges therein.

In some embodiments, the batting comprises a single nonwoven web. In other embodiments, the batting comprises a plurality of nonwoven web layers, wherein one or more of said layers is a nonwoven web according to the disclosure (i.e., containing the fiber mixture and specified weight percentages of assemblages and spaces). In some embodiments, the batting comprises a plurality of nonwoven webs, all of which are nonwoven webs according to the disclosure.

The forming a nonwoven web from the fiber mixture may utilize any acceptable web-forming technology (e.g., an airlaid system, or a carding machine). For example, in some embodiments, the fiber mixture (namely, in the form of assemblages (e.g., the fiberballs 5 and/or the floccules 6), which have been formed from the mixture), is subjected to a flowing air stream to form a nonwoven web. In such embodiments, the spaces may be formed, for example, from “fallout” fiber that has separated from a mixture of assemblages that are processed through the airlaid system.

In some embodiments, forming the nonwoven web comprises depositing the fiber mixture (e.g., the formed assemblages and any loose fibers remaining following formation of the particular three-dimensional structure(s)) onto a forming wire. In some embodiments, this may be done with vacuum assistance (e.g., the vacuum system being located below the forming wire). In particular embodiments, loose assemblages are fed into an air lay system. The air lay system meters out the assemblages via an airflow over a given width and specified thickness.

After the nonwoven web is formed, it is heated to or in excess of the bonding temperature of the binder fibers, thereby forming the inventive batting. For example, after the nonwoven assemblage web is created by the air lay system, it can be carried by an apron into a thermal bonding oven where the binder fibers are activated by heat, thus resulting in a bonded batting.

Prior to thermal bonding (heating the non-woven web to or in excess of the bonding temperature of the binder fibers), the intermediate nonwoven web may optionally be subjected to machining (e.g., rollers) to provide a degree of integrity to the web, if desired (provided, of course, that such machining does not result in a batting that would have a density in excess of 12 kg/m3).

In some embodiments, the insulation or filling material may be formed as a loose or unbonded plurality of the discrete assemblages of the blend of fibers, such as a loose collection of the fiberballs 5 and/or floccules 6 described above. In some such embodiments, the insulation or filling material may also include loose fibers that do not form the discrete assemblages. The loose fibers may or may not be fibers of the blend of fibers forming the assemblages. In some other embodiments, the insulation or filling material may be formed as batting insulation of the discrete assemblages of the blend of fibers being bonded together, as described above. For example, the insulation or filling material may comprise a nonwoven web, as described above.

The insulation or filling material with three-dimensional assemblages of the fiber blend of synthetic and cellulosic fibers including phase change material (whether as loose assemblages or bonded into a non-woven web) of the present disclosure may be incorporated into an article. For example, the insulation or filling material may be positioned within a compartment of an article. Non-limiting examples of such articles include, for example, outerwear (e.g. outerwear garments such as jackets, etc.), clothing, sleeping bags, bedding (e.g., mattresses, mattress toppers/pads, comforters, blankets, sheets, pillows, etc.), footwear (e.g., shoes, boots, slippers, socks, etc.), headwear, bodily protection products (e.g., helmets or worn pads), furniture and furnishings, or any other article that typically includes, or would benefit from the inclusion of, insulation or filling material.

The insulation or filling material of the present disclosure provides a unique combination of a blend fibers 20 of non-phase change fibers and phase change fibers (i.e., fibers including phase change material as a portion thereof) with three-dimensional assemblages/structure (e.g., fiberballs and/or floccules) that provides an unexpected level of thermal performance as compared to other physical forms of insulation or filling material (e.g., traditional layered batting insulation constructs) and/or other blends of fibers. As noted above and shown in FIG. 10, the three-dimensional assemblages/structure (e.g., fiberballs and/or floccules) disclosed herein form a relatively greater amount of internal trapped air spaces 22 as compared to other forms of insulation and filling materials, such as batted insulations and filling materials for example. The three-dimensional structures (e.g., the fiberballs and at least the medial portion of floccules disclosed herein) thereby form a relatively greater amount of internal trapped air spaces 22 near, adjacent, about the fibers 20 of the fiber blend (i.e., the synthetic fibers and the cellulosic fibers) as compared to other forms of insulation and filling materials (e.g., traditional layered batting insulation constructs). The internal trapped air spaces 22 of the three-dimensional structures (e.g., the fiberballs and floccules disclosed herein) provide increased depth and insulative capability as compared to other forms of insulation and filling materials (e.g., traditional layered batting insulation constructs).

The three-dimensional structures (e.g., the fiberballs and at least the medial portion of floccules disclosed herein) of the insulation or filling material thereby provide a unique environment for the unique fiber blend (i.e., the synthetic fibers and the cellulosic fibers) that adds depth and insulative capability. The insulation or filling material of the present disclosure formed by the three-dimensional structures of assemblages of the fiber blend disclosed herein provide an unexpectedly improved temperature control management system (e.g., improved to a greater unobvious extent than expected from the prior art), which provides of a significant, practical advantage, such as compared to insulation or filling material formed of a differing fiber structure/arrangement (e.g., traditional layered batting insulation constructs) and/or the insulation or filling material formed of the same fiber structure/arrangement (e.g., fiberballs and/or floccules disclosed herein) but a differing fiber blend (e.g., without the cellulosic fibers including phase change material). For example, the insulation or filling material of the present disclosure formed by the three-dimensional structures of assemblages of the fiber blend disclosed herein provide unexpectedly improved overall thermal performance (e.g., improved to a greater unobvious extent than expected from the prior art), which provides of a significant, practical advantage, such as compared to insulation or filling material formed of a differing fiber structure/arrangement (e.g., traditional layered batting insulation constructs) and/or the insulation or filling material formed of the same fiber structure/arrangement (e.g., fiberballs and/or floccules disclosed herein) but a differing fiber blend (e.g., without the cellulosic fibers including phase change material). For example, the insulation or filling material of the present disclosure formed by the three-dimensional structures of assemblages of the fiber blend disclosed herein provide unexpectedly improved do per oz/sqyd (e.g., improved to a greater unobvious extent than expected from the prior art), which provides of a significant, practical advantage, such as compared to insulation or filling material formed of a differing fiber structure/arrangement (e.g., traditional layered batting insulation constructs) and/or the insulation or filling material formed of the same fiber structure/arrangement (e.g., fiberballs and/or floccules disclosed herein) but a differing fiber blend (e.g., without the cellulosic fibers including phase change material).

As another example, the insulation or filling material of the present disclosure formed by the three-dimensional structures of assemblages of the fiber blend provides an unexpectedly improved rate at which a user perceives the heating/cooling effect provided thereby (e.g., improved to a greater unobvious extent than expected from the prior art), which provides of a significant, practical advantage, such as compared to insulation or filling material formed of a differing fiber structure/arrangement (e.g., traditional layered batting insulation constructs) and/or the insulation or filling material formed of the same fiber structure/arrangement (e.g., fiberballs and/or floccules disclosed herein) but a differing fiber blend (e.g., without the cellulosic fibers including phase change material). As another example, the insulation or filling material of the present disclosure formed by the three-dimensional structures of assemblages of the fiber blend unexpectedly provides multiple degrees (or levels) of heat storage and heat release within the three-dimensional structures themselves. In a further example, the insulation or filling material of the present disclosure formed by the three-dimensional structures of assemblages of the fiber blend provides an unexpectedly improved fill power (e.g., improved to a greater unobvious extent than expected from the prior art), which provides of a significant, practical advantage, such as compared to insulation or filling material (and/or the three-dimensional structures themselves) formed of the same fiber structure/arrangement (e.g., fiberballs and/or floccules disclosed herein) but a differing fiber blend (e.g., without the cellulosic fibers including phase change material).

The insulation or filling material of the present disclosure formed by the three-dimensional structures of assemblages of the fiber blend of synthetic and cellulosic fibers with phase change material provides a unique heat exchange function: cooling and heating effect. The insulation or filling material provides thermal regulation creating a temperature comfort zone by two components: provide a warming effect when the environment/user's body is cold and a cooling effect when the environment/user's body is warm. The insulation or filling material provides an initial cooling effect that is achieved when heat is removed from the environment/user's body that is in contact with or positioned proximate to the three-dimensional structures (during/after phase change of the phase change material thereof, such as from solid-to-liquid phase change). The insulation or filling material then acts as a heat sink that stores the latent heat when the environment/user's body that is in contact with or positioned proximate to the three-dimensional structures is greater in temperature than that of the insulation or filling material and the phase change temperature of the phase change material incorporated therein. The insulation or filling material thereby provides a heat-sink feature that takes away heat from a hot-bodied source and stores the latent heat therein. When the temperature of the environment/user's body that is in contact with or positioned proximate to the three-dimensional structures is greater in temperature than that of the insulation or filling material and the phase change temperature of the phase change material incorporated therein, the insulation or filling material provides a heating effect releasing the latent heat (during/after phase change of the phase change material thereof, such as from liquid-to-solid phase change).

The insulation or filling material of the present disclosure formed by the three-dimensional structures of assemblages of the fiber blend of synthetic and cellulosic fibers with phase change material thereby creating an insulative material that also has a heat-sinking, heat-exchanging capability (via the phase change material). The insulation or filling material absorbs heat from a heat source, such as the environment created by one's body and/or one's body that is in contact with or is positioned proximate to the material, which creates a cooling effect and an inherent thermal performance which prior insulation and filling material is unable to provide. The insulation or filling material of the present disclosure formed by the three-dimensional structures of assemblages of the fiber blend of synthetic and cellulosic fibers with phase change material thereby also releases heat to the previous heat source, such as the environment created by one's body and/or one's body that is in contact with or is positioned proximate to the material, when the source cools, which creates a heating effect and an inherent thermal performance which prior insulation and filling material is unable to provide.

In some embodiments, the cellulosic fibers with phase change material of the insulation or filling material of the present disclosure formed by the three-dimensional structures of assemblages of the fiber blend of synthetic and cellulosic fibers may include a specific latent heat capacity of greater than 20 J/g (or greater than 50 J/g, greater than 60 J/g, or greater than 90 J/g) in a temperature range from 15 to 45 degrees Celsius, such as a temperature range from 28 to 32 degrees Celsius. For example, as illustrated by the phase change material shown in FIG. 11, the phase change material of the cellulosic fibers of the fiber blend of synthetic and cellulosic fibers forming the three-dimensional assemblages/structures may have a phase change temperature (i.e., melting and solidification temperature) within 15 to 45 degrees Celsius, such as within 28 to 32 degrees Celsius. As shown in FIG. 11 moving from left to right in the image, when the phase change material of the cellulosic fibers is in the liquid phase and the temperature of the phase change material exceeds the phase change temperature, the phase change material liquifies. During the solid-to-liquid phase change, the temperature of the material remains substantially constant such that latent heat/energy is accumulated in the material. In practice, the phase change material thereby absorbs excessive heat and accumulates it. This process can thereby provide a cooling effect upon touch of the insulation or filling material by a user.

As shown in FIG. 11 moving from right to left, when the phase change material of the cellulosic fibers is in the liquid phase and the material is cooled to a temperature below the phase change temperature, the material solidifies (e.g., crystalizes). During the liquid-to-solid phase change, the temperature of the material remains substantially constant such that latent heat/energy is released. In practice, the phase change material thereby releases heat to the surroundings (e.g., a user) of the insulation or filling material (e.g., when it is needed to heat the user).

In these ways, when the insulation or filling material of the present disclosure (formed by the three-dimensional structures of assemblages of the fiber blend of synthetic and cellulosic fibers that include phase change material) is incorporated within an article that comes into contact or close proximity to a user, it can provide an initial cooling effect (given the temperature of the environment is less than the phase change temperature and the temperature of the user's body is greater than the phase change temperature) when the user first uses the article, as shown in the infrared images in FIGS. 12-14. As shown in FIG. 12, the user may initially be at a temperature above the phase change temperature of the cellulosic fibers of the three-dimensional structures of assemblages of the fiber blend of the synthetic and cellulosic fibers of the insulation or filling material. In contrast, as shown in FIG. 13, the insulation or filling material may initially be at a temperature below the phase change temperature. In such a configuration, the insulation or filling material associated/incorporated with the article may absorb the heat from the user when he/she initially comes into contact or close proximity thereto to provide the initial cooling effect, and thereby increase in temperature above the phase change temperature, as shown in FIG. 14. The insulation or filling material may remain at relatively the same temperature above the phase change temperature and absorb latent heat from the user, as shown in FIG. 14. The insulation or filling material stores the latent heat energy for use (i.e., release) later to regulate the user's body temperature when it cools below the phase change temperature, for example, to provide the warming effect.

In one example, the insulation or filling material of the present disclosure (formed by the three-dimensional structures of assemblages of the fiber blend of synthetic and cellulosic fibers that include phase change material) can be incorporated within apparel that is used in an outdoor application, for example, to provide an initial cooling or heating effect that can be felt by the user (depending on the temperature difference between the user's body and the environment the apparel is subjected to (i.e., if the temperature of the phase change material crosses the phase change temperature)). If the temperature of the apparel (and thereby the insulation or filling material) is heated above the phase change temperature, the apparel (i.e., the insulation or filling material thereof) stores heat energy for use later to regulate the user's body temperature when it cools below the phase change temperature, for example.

As another example, the insulation or filling material of the present disclosure (formed by the three-dimensional structures of assemblages of the fiber blend of synthetic and cellulosic fibers that include phase change material) can be incorporated within a furnishing or furniture, for example, to provide an initial cooling effect (given the temperature of the environment is less than the phase change temperature and the temperature of the user's body is greater than the phase change temperature) when the user first uses the furnishing or furniture. The furnishing or furniture (i.e., the insulation or filling material thereof) stores heat energy for use later to regulate the user's body temperature when it cools below the phase change temperature, for example.

In another example, the insulation or filling material of the present disclosure (formed by the three-dimensional structures of assemblages of the fiber blend of synthetic and cellulosic fibers that include phase change material) may be incorporated within a jacket or other outerwear configured for use in relatively cold conditions. A user may be physically active outside on a relatively cold day, such as an outdoor temperature of about 35 degrees Fahrenheit. After the physical activity, the user's body temperature may be raised, and the user may wear the jacket or other outerwear outside such that the user's body temperature raises the temperature of the phase change material above the phase change temperature to melt the phase change temperature and absorb latent heat and, thereby, provide initial cooling effect to the user. Thereafter, the insulating quality of the jacket or other outerwear may keep the user warm (i.e., substantially maintain temperature) until the user removes the jacket or other outerwear (e.g., in a relatively warm dwelling).

As another example, the insulation or filling material of the present disclosure (formed by the three-dimensional structures of assemblages of the fiber blend of synthetic and cellulosic fibers that include phase change material) may be incorporated within a mattress or mattress pad/cover. The mattress or mattress pad/cover may be utilized in a room at a temperature of 72 degrees Fahrenheit. When a user with a body temperature above the phase change temperature of the phase change material of the cellulose fibers of the insulation or filling material with the mattress or mattress pad/cover lays on the mattress or mattress pad/cover, the user's body temperature raises the temperature of the phase change material above the phase change temperature to melt the phase change temperature and absorb latent heat and, thereby, provide initial cooling effect to the user. Thereafter, the mattress or mattress pad/cover maintains a stable environment for the user as the room cools, such as during the night, potentially by releasing the stored latent heat if the temperature of the user/insulation or filling material falls below the phase change temperature.

As yet another example, the insulation or filling material of the present disclosure (formed by the three-dimensional structures of assemblages of the fiber blend of synthetic and cellulosic fibers that include phase change material) may be incorporated within a pillow. When a user with a body temperature above the phase change temperature of the phase change material of the cellulose fibers of the insulation or filling material within the pillow lays on the pillow, the user's body temperature raises the temperature of the phase change material above the phase change temperature to melt the phase change temperature and absorb latent heat and, thereby, provide initial cooling effect to the user. Thereafter, the pillow maintains a stable temperature for the user as the environment and/or person cools, such as during the night, potentially by releasing the stored latent heat if the temperature of the user/insulation or filling material falls below the phase change temperature.

In another example, the insulation or filling material of the present disclosure (formed by the three-dimensional structures of assemblages of the fiber blend of synthetic and cellulosic fibers that include phase change material) may be incorporated within footwear. When a user with a foot temperature above the phase change temperature of the phase change material of the cellulose fibers of the insulation or filling material within the footwear wears the footwear, the user's foot temperature raises the temperature of the phase change material above the phase change temperature to melt the phase change temperature and absorb latent heat and, thereby, provide initial cooling effect to the user's foot. Thereafter, the footwear maintains a stable temperature for the user, and can insulate the user's foot if the user enters a relatively cold environment. If the temperature of the user's foot/footwear falls below the phase change temperature, the insulation or filling material is able to release the latent heat stored by the phase change material and warm the user's foot.

EXAMPLE

The disclosure will now be illustrated, but not limited, by reference to the specific embodiments described in the following example.

A fiber mixture was prepared by mixing 30 wt % 2 denier (2.3 dtex) 20 mm natural cellulose fiber with an integrated phase change material (Cell Solution® CLIMA 2,3); and 70 wt % 2 denier 28 mm solid conjugate siliconize polyester fiber. After being mixed/blended, the fiber mixture was processed into inventive fiberballs via a known process, such one of the processes described above. Similar “standard” fiberballs of the same size and dimension as the inventive fiberballs were similarly manufactured, but without the cellulose fiber with the integrated phase change material.

Physical properties of the inventive fiberballs and the standard fiberballs were compared. For example, the fill power of the inventive fiberballs and the standard fiberballs were compared. The inventive fiberballs were found to have a fill power of 386 cubic centimeters, and the standard fiberballs were found to have a fill power of 350 cubic centimeters. The inclusion of the cellulose fiber with the integrated phase change material in the fiberballs was found to increase the fill power of the fiberballs as compared to the standard fiberballs to an unexpectedly greater extent than one or ordinary skill in the art would expect.

The thermal performance of the inventive fiberballs and the standard fiberballs was compared. The thermal insulating properties of 1.2 inch thicknesses of the inventive fiberballs and the standard fiberballs were tested according to ASTM C518 to determine clo/oz/sqyd. The inventive fiberballs were found to have 0.83 clo/oz/sqyd, and the standard fiberballs were found to have 0.70 clo/oz/sqyd. The inclusion of the cellulose fiber with the integrated phase change material in the fiberballs was found to increase the thermal insulating properties (clo/oz/sqyd) of the fiberballs as compared to the standard fiberballs to an unexpectedly greater extent than one or ordinary skill in the art would expect.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the inventions. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprise” (and any form of comprise, such as “comprises” and “comprising”), “have” (and any form of have, such as “has” and “having”), “include” (and any form of include, such as “includes” and “including”), “contain” (and any form contain, such as “contains” and “containing”), and any other grammatical variant thereof, are open-ended linking verbs. As a result, a method or article that “comprises”, “has”, “includes” or “contains” one or more steps or elements possesses those one or more steps or elements, but is not limited to possessing only those one or more steps or elements. Likewise, a step of a method or an element of an article that “comprises”, “has”, “includes” or “contains” one or more features possesses those one or more features, but is not limited to possessing only those one or more features.

As used herein, the terms “comprising,” “has,” “including,” “containing,” and other grammatical variants thereof encompass the terms “consisting of” and “consisting essentially of.”

The phrase “consisting essentially of” or grammatical variants thereof when used herein are to be taken as specifying the stated features, integers, steps or components but do not preclude the addition of one or more additional features, integers, steps, components or groups thereof but only if the additional features, integers, steps, components or groups thereof do not materially alter the basic and novel characteristics of the claimed compositions or methods.

All publications cited in this specification are herein incorporated by reference as if each individual publication were specifically and individually indicated to be incorporated by reference herein as though fully set forth.

Subject matter incorporated by reference is not considered to be an alternative to any claim limitations, unless otherwise explicitly indicated.

Where one or more ranges are referred to throughout this specification, each range is intended to be a shorthand format for presenting information, where the range is understood to encompass each discrete point within the range as if the same were fully set forth herein.

While several aspects and embodiments of the present inventions have been described and depicted herein, alternative aspects and embodiments may be affected by those skilled in the art to accomplish the same objectives. Accordingly, this disclosure and the appended claims are intended to cover all such further and alternative aspects and embodiments as fall within the true spirit and scope of the inventions. 

1. Insulation or filling material, comprising: a plurality of discrete assemblages of a blend of a plurality of fibers, wherein the blend of fibers comprises: 20 to 80 wt % cellulosic fibers including a phase change material, the fibers having a fiber size less than or equal to 6 denier and a specific latent heat of greater than 20 J/g in a temperature range from 15 to 45 degrees Celsius; and 20 to 80 wt % synthetic polymeric fibers having a fiber size less than or equal to 6 denier, wherein the assemblages form three-dimensional structures with internal air spaces, and wherein the insulation or filling material has at least 0.8 clo/oz/sqyd.
 2. The material according to claim 1, the cellulosic phase change fibers comprising: a cellulose matrix; inclusions within the cellulose matrix comprising one or more nonpolar organic compounds stabilized with at least one hydrophobic thickener; and a barrier material of nanoscale layered particles dispersed in the cellulose matrix.
 3. The material according to claim 2, wherein the density of the barrier material is greater in a zone extending about the inclusions relative to the mean density of the barrier material in the cellulose matrix.
 4. The material according to claim 1, wherein the one or more nonpolar organic compounds have a melting point of less than 100 degrees Celsius and are selected from the group consisting of hydrocarbons, waxes, beeswaxes, oils, fatty acids, fatty acid esters, stearic anhydrides and long-chain alcohols.
 5. The material according to claim 1, wherein the one or more nonpolar organic compounds comprise stabilized paraffin with a melting point within the range of 28 degrees Celsius to 32 degrees Celsius, and wherein the barrier material comprises nanoscale layered silicates.
 6. The material according to claim 1, wherein the cellulosic phase change fibers have a specific latent heat greater than or equal to 50 J/g.
 7. The material according to claim 1, wherein the cellulosic phase change fibers have a fiber size within the range of 2 denier and 3 denier.
 8. The material according to claim 1, wherein the synthetic polymeric fibers comprise first synthetic polymeric fibers having a fiber size of less than 2 denier, and wherein the first synthetic polymeric fibers comprise at least one of siliconized fibers and polyester fibers.
 9. (canceled)
 10. The material according to claim 8, wherein the blend of fibers comprises 10 to 70 wt % the first synthetic polymeric fibers.
 11. The material according to claim 8, wherein the synthetic polymeric fibers comprise second synthetic polymeric conjugate fibers, wherein the second synthetic polymeric fibers comprise at least one of siliconized fibers and polyester fibers.
 12. (canceled)
 13. The material according to claim 11, wherein the second synthetic polymeric fibers are conjugate crimped fibers.
 14. The material according to claim 11, wherein the blend of fibers comprises 10 to 70 wt % the second synthetic polymeric fibers.
 15. The material according to claim 1, wherein at least one of the synthetic polymeric fibers and the cellulosic phase change fibers have a staple fiber length of 20 mm to 40 mm.
 16. The material according to claim 1, having a fill power greater than 350 cubic centimeters.
 17. The material according to claim 1, wherein the three-dimensional structures comprise fiberballs having an average diameter of 3 mm to 10 mm.
 18. (canceled)
 19. The material according to claim 17, wherein the fiber blend further comprises binder fibers have a bonding temperature lower than a softening temperature of the cellulosic fibers and the synthetic polymeric fibers.
 20. The material according to claim 17, comprising: 50 to 95 wt % of a plurality of the fiberballs formed of the fiber blend having an average diameter of 3.0 to 8.0 mm; and 5 to 50 wt % of the fiber blend being adjacent to one or more fiberballs but that do not themselves comprise one or more fiberballs or any portion thereof.
 21. The material according to claim 19, wherein the fiberballs and the fiber blend adjacent to one or more fiberballs but that do not themselves comprise one or more fiberballs or any portion thereof forms a batting insulation.
 22. The material according to claim 1, wherein the three-dimensional structures comprise discrete longitudinally elongated floccules, the floccules including a relatively open enlarged medial portion and relatively condensed twisted tail portions extending from opposing ends of the medial portion.
 23. The material according to claim 22, wherein the longitudinal length of the floccules is within the range of 2 cm to 4.5 cm, the longitudinal length of the medial portion of the floccules is within the range of 0.1 cm to 2 cm, and the longitudinal length of the tail portions of the floccules is within the range of 0.8 cm to 1.8 cm.
 24. An article, comprising: the insulation or filling material according to claim 1 positioned within a compartment of the article.
 25. The article according to claim 24, wherein said article is selected from the group consisting of an outerwear product, clothing, footwear, headwear, a sleeping bag, bedding and a furniture product.
 26. A method of making the insulation or filling material according to claim 1, said method comprising: mixing the blend of fibers comprising: 20 to 80 wt % cellulosic fibers having phase change material, a fiber size less than 6 denier and a specific latent heat of greater than 20 J/g in a temperature range from 15 to 45 degrees Celsius; and 20 to 80 wt % synthetic polymeric fibers having a fiber size less than 6 denier, and forming a plurality of assemblages from the fiber mixture having a three-dimensional structure with internal air spaces, and wherein the insulation or filling material has at least 0.8 clo/oz/sqyd.
 27. The method according to claim 26, wherein forming the plurality of assemblages from the fiber mixture comprises: forming fiberballs having an average diameter of 3 mm to 10 mm from the fiber mixture; or forming discrete longitudinally elongated floccules from the fiber mixture, the floccules including a relatively open enlarged medial portion and relatively condensed twisted tail portions extending from opposing ends of the medial portion.
 28. (canceled) 